Breast cup and method of manufacture

ABSTRACT

There is provided a breast cup for a brassiere comprising an outer layer and an inner layer attached to the outer layer. The breast cup also comprises first and second opposing pieces of fabric positioned between the inner and outer layers, wherein the first and second opposing pieces of fabric are preferably affixed to the inner and outer layers respectively. At least a portion of the first opposing piece of fabric is movable relative to at least a portion of the second opposing piece of fabric. A method of manufacturing the breast cup is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

Chinese patent application no. 201310072551.4, filed on Mar. 7, 2013, is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a breast cup for a brassiere or other underwear, tight clothing or swimwear, and, in particular, a breast cup comprising multiple layers. A method of manufacturing the breast cup is also provided.

BACKGROUND OF THE INVENTION

A conventional brassiere comprises a pair of breast cups, a centre gore, a back strap or pair of wings which extend around the back of the wearer, and, optionally, straps which extend over the shoulders of the wearer from the breast cups to attachment points on the back wings or strap. A brassiere may also include an underwire for each breast cup to shape and support the lower periphery of each breast cup.

A known method for manufacturing a multi layered breast cup comprises spraying multiple panels or layers with adhesive, assembling them in a planar form and then moulding the assembly into a breast cup shape, with the layers or panels being adhered across their surfaces.

There is a continuing need to provide a breast cup with increased comfort and cushioning and a method for manufacturing such a breast cup.

SUMMARY OF THE INVENTION

In a first aspect of the invention there is provided a breast cup comprising an outer layer, an inner layer attached to the outer layer, and first and second opposing pieces of fabric positioned between the inner and outer layers, the first and second opposing pieces of fabric being preferably affixed to the inner and outer layers respectively, wherein at least a portion of the first opposing piece of fabric is movable relative to at least a portion of the second opposing piece of fabric.

In a second aspect of the invention, there is provided a molded brassiere comprising a first breast cup and a second breast cup wherein each breast cup comprises; an outer layer; an inner layer; and first and second opposing pieces of fabric positioned between the inner and outer layers, the first and second opposing pieces of fabric being preferably affixed to the inner and outer layers respectively; wherein at least a portion of the first opposing piece of fabric is moveable relative to at least a portion of the second opposing piece of fabric.

The benefit of the breast cup according to the present invention is that it may have an improved feel or comfort or cushioning effect due to the relative movement between the first and second opposing pieces of fabric.

By “movable relative to each other” it is meant that there is at least one region where the first and second opposing pieces of fabric are not affixed to each other such that it is possible to slide at least a portion of the first piece over at least a portion of the second piece, whether in direct contact with one another or in contact via an intermediary material.

By “affixed to the inner and outer layers respectively” it is meant that the first and second opposing pieces of fabric are physically attached to the inner and outer layers, whether by adhesive, stitching, fusing or some other suitable means.

Although it is preferred that the first and second opposing pieces of fabric are affixed to the inner and outer layers respectively, such affixing may not be necessary so that the first and second opposing pieces of fabric may remain un-affixed to the inner and outer layers.

In a first embodiment of the breast cup, the relative movement between the first and second opposing pieces of fabric is in a region of the lower portion of the cup which provides support and uplift.

In a second embodiment of the breast cup, the relative movement between the first and second opposing pieces of fabric is over substantially the entire cup.

In a third embodiment of the breast cup, the breast cup further comprises an underwire positioned between the outer layer and the second opposing piece of fabric. The relative movement between the first and second opposing pieces of fabric is in the region of the underwire. The benefit of locating the relative movement between the opposing pieces in this region is that may increase the comfort of the wearer by decreasing friction between the underwire and the rest of the breast cup and may provide an improved cushioning effect.

Preferably, the first and second opposing pieces of fabric consist of fabric that facilitates the relative movement between the pieces.

A gap may be provided between the first and second opposing pieces of fabric. Alternatively, the breast cup may comprise a filler material provided between the first and second opposing pieces of fabric.

The breast cup is preferably a molded breast cup.

At least one of the inner and outer layers of the breast cup may comprise a fabric-foam laminate. The foam is preferably polyurethane foam. Alternatively, or in addition, at least one of the inner and outer layers of the breast cup may comprise at least one layer of fabric.

The first and second opposing pieces of fabric may be affixed to each other along at least a portion of the periphery of the opposing pieces of fabric. The first and second opposing pieces of fabric may be of substantially the same size and shape.

In a third aspect of the invention there is provided a method for producing a breast cup comprising providing an inner layer, providing an outer layer, providing first and second opposing pieces of fabric between the inner and outer layers and affixing the inner layer to the outer layer and preferably affixing the first and second opposing pieces of fabric to the inner and outer layers respectively, wherein at least a portion of the first opposing piece of fabric is movable relative to at least a portion of the second opposing piece of fabric. The benefit of the breast cup produced according to this method is that it may have an improved feel or comfort or cushioning effect due to the relative movement between the first and second opposing pieces of fabric.

Preferably, the method comprises the further steps of spraying the inner and outer layers with adhesive, placing the first and second opposing pieces of fabric between the inner and outer layers, and moulding the inner and outer layers with the opposing pieces of fabric therebetween to form a molded breast cup.

Preferably, the step of moulding the inner and outer layers with the opposing pieces of fabric therebetween comprises moulding one of the inner and outer layers by itself, and then moulding, as a set, the inner and outer layers with the opposing pieces of fabric therebetween.

The relative movement between the first and second opposing pieces of fabric may be provided in a region of the lower portion of the cup which provides support and uplift.

The relative movement between the first and second opposing pieces of fabric may be provided over substantially the entire cup.

The method may further comprise placing an underwire between the outer layer and the second opposing piece of fabric and wherein the relative movement between the first and second opposing pieces of fabric is provided in the region of the underwire.

The method may further comprise the step of affixing the first and second opposing pieces of fabric to each other along at least a portion of the periphery of the opposing pieces of fabric.

The method may further comprise the step of providing a filler material between the first and second opposing pieces of fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in detail with reference to the accompanying drawings, in which:

FIG. 1A shows a breast cup according to a first embodiment of the invention;

FIG. 1B shows a cross section of the breast cup shown in FIG. 1A;

FIG. 2A shows a breast cup according to a second embodiment of the invention;

FIG. 2B shows a cross section of the breast cup shown in FIG. 2A;

FIG. 3A shows a breast cup according to a third embodiment of the present invention;

FIG. 3B shows a cross section of the breast cup shown in FIG. 3A;

FIG. 4A shows a breast cup according to a fourth embodiment of the present invention;

FIG. 4B shows a cross section of the breast cup shown in FIG. 4A;

FIG. 5A shows the steps for producing a breast cup according to the method of the present invention;

FIG. 5B shows a pair of breast cups produced according to the method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

A breast cup in accordance with the present invention will now be described with reference to FIGS. 1A to 4B. The breast cup of the preferred embodiments is a molded breast cup.

A first preferred embodiment of a breast cup according to the present invention is shown in FIGS. 1A and 1B. As shown in FIG. 1B breast cup 100 comprises inner layer 110, outer layer 120 and first and second opposing pieces of fabric 103, 104 therebetween. First piece of opposing fabric 103 and second piece of opposing fabric 104 are affixed to inner layer 110 and outer layer 120 respectively, and at least a portion of the first and second opposing pieces of fabric 103, 104 are movable relative to each other in a region of the lower portion 10 of the cup which provides support and uplift. Inner layer 110 is affixed to outer layer 120 to form a completed breast cup shown in FIG. 1A.

As shown in FIG. 1B, inner layer 110 preferably comprises a fabric layer 111, a first molded foam layer 112 and a second molded foam layer 113. Similarly, the outer layer 102 preferably comprises a fabric layer 121, a first molded foam layer 122 and a second molded foam layer 123. The outermost layers of the inner and outer layers are the fabric layers 111, 121.

In variations of the first embodiment, in accordance with the invention, the inner and outer layers 110, 120 may comprise different structures to that described above, for example the inner and outer layers 110, 120 may comprise a single fabric layer, a single foam layer combined with fabric or more than two layers of foam combined with fabric.

In the first preferred embodiment of the invention, the relative movement between the opposing pieces of fabric occurs in the lower portion 10 of the cup which provides support and uplift. By providing relative movement in the lower portion of the breast cup, the breast cup may provide an improved cushioning effect or improved comfort for the wearer.

FIG. 2B shows a cross section of a breast cup 200 according to a second preferred embodiment of the present invention. The breast cup comprises inner layer 210 and outer layer 220. Inner layer 210 and outer layer 220 consist of a layer of fabric, which may be molded into a breast cup shape. Breast cup 200 also comprises first and second opposing pieces of fabric 203, 204 which are affixed to inner layer 210 and outer layer 220 respectively. As shown in FIGS. 2A and 2B, the region 20 of relative movement between the first and second opposing pieces of fabric 203, 204 is over substantially the entire cup.

Although the preferred embodiment is shown with a single fabric layer inner layer and single fabric layer outer layer, variations of the second embodiment, in accordance with the present invention can comprise inner and outer layers that also include one or more foam layers.

A particularly preferred variant of the second embodiment is depicted in FIG. 3B which shows a cross section of a breast cup according to a third preferred embodiment of the present invention. As with the second embodiment, the breast cup comprises inner and outer layers 310, 320, with first and second opposing pieces of fabric 303, 304 therebetween, wherein the relative movement between the first and second opposing pieces of fabric 303, 304 is provided over substantially the entire cup in region 30, as shown in FIG. 3A. However, in this embodiment inner and outer layers 310, 320 each comprise a fabric-foam layer, i.e. 311-312 and 321-322 respectively.

FIG. 4B shows a cross section of a breast cup according to a fourth preferred embodiment of the present invention. The breast cup comprises inner and outer layers 410, 420, wherein the inner and outer layers 410, 420 comprise fabric layers 411, 421, first foam layers 412, 422 and second foam layers 413, 423 respectively, with first and second opposing pieces of fabric 403, 404, therebetween. First opposing piece of fabric 403 is affixed to inner layer 410 and second opposing piece of fabric 404 is affixed to outer layer 420. The breast cup also comprises an underwire 406 positioned between the outer layer 420 and the second opposing piece of fabric 404. The region 40 of relative movement between the first and second opposing pieces of fabric 403, 404 is in the region of underwire 406.

By providing the relative movement of the first and second pieces of fabric 403, 404 in the region 40 of the underwire 406, on the user-side of the underwire, the breast cup of the present invention may provide improved cushioning and comfort to the wearer and reduce friction between the underwire and the rest of the breast cup. Should the underwire be provided or encased in an underwire sock, the reduced friction provided by the relative movement of the opposing fabric pieces 403, 404 may reduce the likelihood of the underwire piercing an underwire sock during washing.

Although the fourth preferred embodiment, as depicted in FIGS. 4A and 4B comprises an inner and outer layer 410, 420 which each comprise two foam layers and a fabric layer, in variations of the embodiment in accordance with the invention, the inner and outer layers could instead comprise a single foam layer or more than two foam layers in combination with a fabric layer. Alternatively, the inner and outer layers could each comprise one or more fabric layers, without a foam layer.

Although the breast cups as described above with reference to FIGS. 1A to 4B have been described as having an inner layer with a layer structure which is similar to the layer structure of the outer layer, this need not be the case and the inner and outer layers could be provided with different layer structures. For example the inner layer of the breast cup could have two foam layers combined with a fabric layer, whilst the outer layer has a single foam layer combined with a fabric layer, etc.

The inner and outer layers may comprise foam layers of varying thickness. For example, as shown in embodiments 1 and 4, the breast cup may be constructed of foam layers with thicknesses such that there is more cushioning and support provided in the lower region of the breast cup. This may improve comfort for the wearer and provide improved uplift.

Preferably, the inner most layer of the inner layer and the outer most layer of the outer layer comprise a fabric layer or the fabric side of a fabric-foam laminate. By providing a fabric layer closest to the wearer's skin and on the outer surface of the brassiere, the brassiere will have a smoother surface less visible under clothing and be more comfortable for the wearer.

As described in the four preferred embodiments above, the region of relative movement between the first and second opposing layers, may be in various region of the breast cup or in the underwire region.

Since the present invention provides a region of the breast cup in which there is relative movement between the first and second opposing pieces, it is preferable that all of the aforementioned embodiments comprise opposing pieces of fabric consisting of a fabric with a smooth surface that facilitates the relative movement between the pieces, for example a satin-like or silky material. It is also preferable that the first and second opposing pieces of fabric are of substantially the same shape and size.

FIGS. 1A to 4B illustrate the first and second opposing pieces of fabric being spaced apart from one another, with a gap therebetween. An air space may be provided between the first and second opposing pieces of fabric. However, the first and second opposing pieces of fabric are preferably substantially adjacent or in direct contact with each other such that they slide across each other in the region of relative movement. Alternatively, a filler material may be provided between the first and second opposing pieces of fabric in any of the described embodiments of the invention, to provide increased cushioning or uplift. This filler may be provided in one region of the breast cup, for example the lower portion of the breast cup where a conventional “cookie” would be placed, over substantially the entire cup or in the region of the underwire. For example, a gel substance or foam filler may be provided between first and second opposing pieces of fabric.

If a filler is provided, it is preferable to include a filler in the first and fourth preferred embodiments of the invention, i.e. in the lower region 10 of the breast cup as shown in the first embodiment or in the region 40 of the underwire in the fourth embodiment of the invention. The filler may provide support and uplift in the first embodiment and improved cushioning from the underwire in the fourth embodiment. If a filler is used, at least one of the first and second opposing pieces of fabric is substantially movable relative to the filler and thus relative to the other opposing piece of fabric.

In the embodiments described above, the first and second opposing pieces of fabric are substantially free to move relative to each other across the whole surface of the first and second opposing pieces of fabric. However, this need not be the case. In accordance with the invention, only a part of the first and second opposing pieces of fabric may be free to move relative to each other. For example, the first and second opposing pieces of fabric may be affixed to each other around all or part of the periphery of the opposing pieces of fabric.

A method of manufacturing the above described breast cups will now be described.

A method of manufacturing the breast cup in accordance with the present invention comprises providing an outer layer 505, providing an inner layer 502, and providing first and second opposing pieces of fabric 503, 504 between the inner and outer layers. The method further comprises affixing the inner layer 502 to the first opposing fabric piece 503 and the outer layer 505 to the second opposing fabric piece 504. The inner layer 502 and outer layer 505 are then affixed to each other such that at least a portion of the first opposing piece of fabric is movable relative to at least a portion of the second opposing piece of fabric

As described in the preferred embodiments of a breast cup above, the relative movement between the first and second opposing layers may be provided in different regions of the breast cup. In particular, the relative movement between the first and second opposing pieces of fabric may be provided over substantially the entire cup, in the lower portion of the cup which provides support and uplift or, when an underwire is provided, in the region of the underwire.

The preferred method of manufacturing the breast cup is to mould the layers of the breast cup under heat and pressure. This preferred method of manufacture will be described with reference to FIG. 5. The method preferably involves using a two-part mould comprising a first mould half 506 and a second mould half 501. In a preferred embodiment, the outer layer 505 of the breast cup is molded over the first mould half 506 to form a breast cup shape. Adhesive is then applied to the outer layer 505, and opposing pieces of fabric 503, 504 are then placed on the molded outer layer 505. Adhesive is sprayed onto the inner layer 502 of the breast cup and the inner layer 502 is placed, adhesive-side down, onto the outer layer 505. The second mould half 501 is placed on top of the layers and the layers are molded into a breast cup by application of heat and pressure.

In the moulding process all surfaces bearing adhesive will adhere to surfaces into which they are placed into contact. First opposing piece 503 will adhere to inner layer 502 and second opposing piece 504 will adhere to outer layer 505. No adhesive is applied to the first opposing piece of fabric 503 or the second opposing piece of fabric 504. Thus, when molded, the first and second opposing pieces 503, 504 which overlap with one another remain un-adhered to each other and substantially free to move relative to each other. For this reason, it is preferable that first and second opposing pieces of fabric 503, 504 are substantially the same size and shape and are substantially aligned upon placement onto outer layer 505.

By moulding the outer layer 505 prior to assembly and application of adhesive, it is easier to place the first and second opposing pieces of fabric in the correct region of the breast cup.

Although, in the preferred method described above, no adhesive is applied to the first and second opposing pieces of fabric, this is not a requirement. In accordance with a variation of the described method, adhesive may be applied along the periphery of the opposing pieces of fabric, as long as there is a region in which the pieces of fabric remain substantially free to move relative to each other, e.g. across the core of the opposing pieces of fabric.

The moulding process may produce a single breast cup or, more preferably and as shown in FIG. 5A, both breast cups 507 may be produced in a single mould 501, 506. The breast cup ensemble shown in FIG. 5A may be trimmed to form two breast cups 507 as shown in FIG. 5B.

While this description primarily describes the embodiments of breast cup for a brassiere, the invention is also applicable to breast cup for other underwear, tight clothing and swimwear.

It will be appreciated that this description is by way of example only; alterations and modifications may be made to the described embodiment without departing from the scope of the invention as defined in the claims. 

1. A breast cup comprising: an outer layer; an inner layer attached to the outer layer; and first and second opposing pieces of fabric positioned between the inner and outer layers; wherein at least a portion of the first opposing piece of fabric is movable relative to at least a portion of the second opposing piece of fabric.
 2. The breast cup of claim 1, wherein the first and second opposing pieces of fabric are affixed to the inner and outer layers respectively.
 3. The breast cup of claim 1, wherein the relative movement between the first and second opposing pieces of fabric is in a region of the lower portion of the cup which provides support and uplift.
 4. The breast cup of claim 1, wherein the relative movement between the first and second opposing pieces of fabric is over substantially the entire cup.
 5. The breast cup of claim 1, wherein the breast cup further comprises an underwire positioned between the outer layer and the second opposing piece of fabric and the relative movement between the first and second opposing pieces of fabric is in the region of the underwire.
 6. The breast cup of claim 1, wherein the first and second opposing pieces of fabric consist of fabric that facilitates the relative movement between the pieces.
 7. The breast cup of claim 1, wherein a gap is provided between the first and second opposing pieces of fabric.
 8. The breast cup of claim 1, further comprising a filler material provided between the first and second opposing pieces of fabric.
 9. The breast cup up of claim 1, wherein the breast cup is a molded breast cup.
 10. The breast cup of claim 1, wherein at least one of the inner and outer layers comprises a fabric-foam laminate.
 11. The breast cup of claim 1, wherein the first and second opposing pieces of fabric are affixed to each other along at least a portion of the periphery of the opposing pieces of fabric.
 12. A method for producing a breast cup comprising: providing an inner layer; providing an outer layer; providing first and second opposing pieces of fabric between the inner and outer layers; and affixing the inner layer to the outer layer, wherein at least a portion of the first opposing piece of fabric is movable relative to at least a portion of the second opposing piece of fabric.
 13. The method of claim 12, further comprising the step of affixing the first and second opposing pieces of fabric to the inner and outer layers respectively.
 14. The method of claim 12, further comprising the steps of: spraying the inner and outer layers with adhesive; placing the first and second opposing pieces of fabric between the inner and outer layers; and moulding the inner and outer layers with the opposing pieces of fabric therebetween to form a molded breast cup.
 15. The method of claim 14, wherein the step of moulding the inner and outer layers with the opposing pieces of fabric therebetween comprises moulding one of the inner and outer layers by itself, and then moulding, as a set, the inner and outer layers with the opposing pieces of fabric therebetween.
 16. The method of claim 12, wherein the relative movement between the first and second opposing pieces of fabric is provided in a region of the lower portion of the cup which provides support and uplift.
 17. The method of claim 12, wherein the relative movement between the first and second opposing pieces of fabric is provided over substantially the entire cup.
 18. The method of claim 12, wherein the method further comprises placing an underwire between the outer layer and the second opposing piece of fabric and wherein the relative movement between the first and second opposing pieces of fabric is provided in the region of the underwire.
 19. The method of claim 12, further comprising the step of affixing the first and second opposing pieces of fabric to each other along at least a portion of the periphery of the opposing pieces of fabric.
 20. A molded brassiere comprising a first breast cup and a second breast cup wherein each breast cup comprises: an outer layer; an inner layer; and first and second opposing pieces of fabric positioned between the inner and outer layers, the first and second opposing pieces of fabric affixed to the inner and outer layers respectively; wherein at least a portion of the first opposing piece of fabric is moveable relative to at least a portion of the second opposing piece of fabric. 